Building construction

ABSTRACT

A BUILDING CONSTRUCTION COMPRISING MODULAR CROSS ARM COLUMNS, FLOOR SLABS, BUILDING SLABS AND RELATED STRUCTURES IS PROVIDED. THE WALL PANELS WHICH MAY BE USED AS INTERIOR WALL PANELS HAVE AT LEAST ONE SIDE EDGE CARRYING AN ELONGATED FASTENING MEANS FOR INTERLOCKING WITH AN EDGE OF AN ADJACENT WALL PANEL AND FOR PREVENTING MOVEMENT OF SUCH INTERLOCKED PANELS DIRECTLY AWAY FROM EACH OTHER WHILE PERMITTING SLIDING OF SAID PANELS ALONG A LINE FIXED WITH RESPECT TO EACH OTHER AND SUBSTANTIALLY PARALLEL TO THE ONE SIDE EDGE. THE FASTENING MEANS COMPRISES HOOK MEANS FOR POSITIVELY PREVENTING MOVEMENT OF TWO INTERLOCKED PANELS DIRECTLY AWAY FROM EACH OTHER WITHOUT FIRST DESTROYING THE HOOK MEANS.

Feb. 16, 1971 E. ALI-OGLU BUILDING CONSTRUCTION 7 Sheets-Sheet 1Original Filed Feb. 15. 1966 INVENTOR BY A E. ALI-OGLU 3,562,978

BUILDING CONSTRUCTION 7 Sheets-Sheet 2 FIG. 6

Feb. 16, 1971 Original Filed Feb. 15. 1966 INVEN R FIG. 70

Feb. 16, 1971 E. ALI-OGLJJ BUILDING CONSTRUCTION 7 SheetsSheet 3Original Filed Feb. 15. 1.966

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l o" H. Il d-ca INVENTOR Que BY 9* m 2 ATTOR Feb. 16, 1971 ALI-OGLU3,562,978

BUILDING CONSTRUCTION Original Filed Feb. 15. 1966 7 Sheets-Sheet 4.

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INVENTOR BY l" Feb. 16, 1971 E. ALI-OGLU BUILDING CONSTRUCTION 7Sheets-Sheet 5 Original Filed Feb. 15. 1966 FIG. 7f

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Feb. 16, 1971 E. ALI-OGLU BUILDING CONSTRUCTION i i I i iti o Illll-lillll ll llilfillllllllli .Ilir! lllllllllllllllllllllllllll llm lfi.

7 SheetsSheet 6 FIG. 24

INVENTOR ATTORNEY FIG. 23

ltllll Original Filed Feb. 15'. 1966 Feb. 16, 1971 E. ALI-OGLU 3,562,978

BUILDING CONSTRUCTION Original Filed F91). 15. 1966 7 Sheets-Sheet 7 I Ii INVENTOR ATTORNEY United States Patent US. Cl. 52122 12 ClaimsABSTRACT OF THE DISCLOSURE A building construction comprising modularcross arm columns, floor slabs, building slabs and related structures isprovided. The wall panels which may be used as interior wall panels haveat least one side edge carrying an elongated fastening means forinterlocking with an edge of an adjacent wall panel and for preventingmovement of such interlocked panels directly away from each other whilepermitting sliding of said panels along a line fixed with respect toeach other and substantially parallel to the one side edge. Thefastening means comprises hook means for positively preventing movementof two interlocked panels directly away from each other without firstdestroying the hook means.

This application is a continuation in part of US. patent applicationSer. No. 527,450 filed Feb. 15, 1966 and now abandoned.

The present invention relates to building construction and moreparticularly to modular building structures and prefabricated componentsfor use in forming such structures. The invention is useful to permitbuilding of a great variety of structures with a minimum amount ofmodule components and can be used for homes, schools, oflices and otherstructures.

Prefabricated constructions are well known in the building industry butare often limited in usage due to cost, difiiculty of assembly, lack ofversatility or other reasons.

An important object of this invention is to provide a modular buildingconstruction which provides for great rigidity and strength with a smallnumber of module units which can be rapidly and economically assembledto form a variety of structures.

Another important object of this invention is to provide a plurality ofrelatively inexpensive components for use in the building constructionin accordance with the preceding object.

Still another object of this invention is to provide a means and methodfor reducing the Weight of cast or molded components of a prefabricatedor other cement type construction which means and method are inexpenvsive and simple to use.

Another object of this invention is to provide a means and method inaccordance with the preceding object utilizing paper products which arecompacted for storage and shipment and rapidly expandable for use.

According to the invention, a modular building construction comprises abuilding skeleton made up of a plurality of concrete columns with eachcolumn carrying integral radiating arms in cross formation. Ends of thearms of one column are rigidly joined to the ends of the arms of atleast one other column to form a rigid modular building frame. Aplurality of concrete floor/ceiling slabs rest on the radiating arms.Preferably adjacent cross arms are rigidly joined together throughintermediate tie beams. The building frame or skeleton is covered withconcrete exterior wall slabs in module form or with lightweightinterlocking modular panels and the interior of the building frame canbe divided into suitable rooms or compartments by the use of module wallpanels carrying interconnecting or locking means at their edges.

Preferably, the columns, cross arms, tie beams, fioor/ ceiling slabs andouter wall slabs are formed of concrete. The floor/ceiling slabs andwall slabs are preferably provided with hollow spaces to reduce weightwhile maintaining cross sectional area and strength over long spans. Thehollow spaces are preferably provided by the use of inexpensive corespositioned in molds when the slabs or other concrete members are formed.Preferably the cores are constructed to allow flat shipment and compactstorage yet provide for expansion into rigid forms of substantial size.

It is a feature of the invention that the skeleton construction of thecolumns, cross arms and tie beams used provides rigidity and acts as ameans for mounting wall panels and other components of varying typeswithout the need for said wall panels and other components providingstrength or rigidity to the overall building construction.

These and other features, objects and advantages of the presentinvention will be better understood from the following specificationwhen read in conjunction with the accompanying drawings in which:

FIG. 1 is an exploded view of a preferred embodiment of a buildingconstruction in accordance with the present invention;

FIGS. 2, 2a and 2b are top views of module floor slabs thereof;

FIG. 3 is a cross sectional view taken through line 33 of FIG. 1;

FIG. 4 is a cross sectional view taken through line 44 of FIG. 1;

FIG. 5 is a cross sectional view taken through line 5-5 of FIG. 1showing a completed joint between two side edges of two fioor slabsresting on a cross arm tie beam joint;

FIG. 6 is a cross sectional view taken through line 66 of FIG. 1 showinga completed joint;

FIG. 6a is a top view of the joint shown in FIG. 6;

FIG. 7 is a cross sectional view taken through a completed joint betweentwo axially extending columns and cross arm members taken along line 7-7of FIG. 1;

FIG. 7a is a top plan view of the joint shown in FIG. 7 taken along line7a7a thereof;

FIGS. 7b, 7c, 7d, 7e and 7] are cross sectional views taken on avertical plane through the center of aligned columns in alternate jointconstructions of this invention;

FIGS. 7g, 7h, 7i, 7 and 7k are cross sectional views through lines 7g7gof FIG. 7b, 7h7h of FIG. 7c, 7i-7i of FIG. 7d, 7j-7j of FIG. 7e and 7k7kof FIG. 7 respectively;

FIG. 8 is a top plan view of a column and cross arm component of thisinvention;

FIG. 8a is a side view thereof;

FIG. 9 is a top plan view of a preferred embodiment of a tie beamcomponent;

FIG. 9a is a side view thereof;

FIG. 10 is a side view of an exterior wall slab of this invention;

FIG. 11 is a top plan view thereof;

FIGS. 11a, 11b, and are top plan views of alternate sizes for moduleexterior wall slabs as illustrated in FIGS. 10 and 11;

FIG. 12 is a top plan view of an alternate embodiment oi the exteriorwall slabs of this invention;

FIG. 13 is an exploded view of a connector useful in the preferredembodiment of this invention;

FIG. 14 is a side view of a joint between components of this invention;

FIG. is a top plan view of still another joint construction inaccordance with this invention;

FIG. 16 is an enlarged plan view of the element shown in FIG. 12positioned with respect to a column member of this invention;

FIGS. 17. 17a, 17b, 17c and 17d illustrate diagrammatically various sizeinternal wall panels useful in the building construction of thisinvention;

FIG. 18 is an exploded perspective view of two adjacent interior wallpanels of this invention and a connector element;

FIG. 19 is a cross sectional view on a vertical plane through anotherjoint construction of this invention;

FIG. 20 is a cross sectional view on a horizontal plane through a jointbetween four interior wall panels in accordance with this invention;

FIG. 21 is a cross sectional view on a vertical plane through aninterior wall panel of this invention joined to a ceiling;

FIG. 22 is a cross sectional view on a vertical plane through aninterior wall panel of this invention joined to a floor;

FIG. 23 is a cross sectional view on a horizontal plane through a doorframe joint construction in accordance with the present invention;

FIG. 24 is an end view of a gasket strip of this invention;

FIGS. 25, 25a, 25b and 26 are cross sectional views taken on horizontalplanes through alternate joint constructions of the type shown in FIG.18;

FIG. 27 is a fragmentary perspective view of a core element inaccordance with this invention;

FIG. 28 is a plan view of a blank for the coring element shown in FIG.27;

FIG. 29 is a fragmentary perspective view of an alternate embodiment ofthe coring element of this invention;

FIG. 30 is a plan view of a blank thereof; and

FIGS. 31 and 32 are perspective views of alternate embodiments of coringelements in accordance with this invention.

With reference now to the drawings and more particularly FIG. 1, abuilding construction 10 in exploded form is shown made up of columncomponents 11, tie beams 30, floor/ceiling slabs 12, 13 and 14 andexterior wall slabs 15. All of these components are prefabricatedpreferably of cement or other cementious type material commonly used inthe building industry. By selecting predetermined module sizecomponents, a variety of structures can be built with a minimum numberof diverse size components. In the preferred embodiment, the componentsare dimensioned on a four foot square module unit although otherpreselected sizes can be used.

The building skeleton is made up of groups or modules preferablycomprising four column components 11 vertically arranged to form a firstlevel upon which can be placed additional column components to provide asecond or any practical number of additional layers or floors in abuilding construction. Similarly additional modules can be formed on asingle level by adding additional columns 11. wall slabs l5 andfloor/ceiling slabs if desired. Each column 11 has a vertical portion 16carrying at its upper end integral cross arms 17, 18, 19 and 20preferably of equal size. The arms 17-20 lie substantially in a planeperpendicular to the axis of column portion 16. The end of each crossarm is formed with a recess 21 defined by vertical walls 22 and 23connected at their bottoms by a horizontal wall 24.

As best shown in FIGS. 1, 8 and 8a, reinforcing rods 25 extendlongitudinally through the vertical column portion 16 of each columncomponent preferably adjacent each of the four corners and outwardly ofthe upper end. Extension rods 25a are welded or otherwise joined to thelower ends of each rod 25 and extend downwardly of the lower end of eachportion 16. Similarly, reinforcing rods 26 extend adjacent the fourcorners of each lll of the cross arms past the end walls 27 of therecesses and freely into the recesses 21. The reinforcing rods 25 and 26are known in precast concrete construction and conventional weight rodscan be used and positioned in the columns and tie beams duringfabrication using conventional procedures. In some cases the rods can bere placed with wire elements or other common reinforcing means forconcrete construction. Preferably transversely extending wire elements41 are provided at spaced intervals embedded in the cross arms. tiebeams and column portions 15 surrounding the rods 25 and 26 and act asadditional reinforcements as is shown in the art.

In the preferred embodiment tie beams 30 best shown in FIGS. 1, 9 and 9aare used extending between ends of longitudinally aligned arms. The tiebeams preferably have cross sections equal to the cross section of thearms of the column components 11 and are similarly fitted with recesses21' identical with recesses 21.

Rigid joints are formed between tie beam ends and arm ends as shown inFIGS. 6 and 6a. The ends are butted as shown in FIG. 6 with the recesses21 and 21 facing each other to form a basically rectangular hollowrecess. Preferably the ends of rods 26 at the upper portion of both thearms and tie beams are inclined downwardly at an angle and then freelyoutwardly parallel with the lower rods 26 of arms 19 and tie beams 30.Similar rods 26 of the tie beams butt the rods 26 of the arms and acollar 31 is crimped over each of the free butting rod ends to formrigid joints thercbetween. After the collars 31 are criinped the hollowrecesses formed by recesses 21 and 21' are then filled with a groutingmaterial of any conventional nature which may be for exampleconventional hydraulic cement. Thus. a strong. rigid joint can be formedbetween the ends of the arms and the tie beams as in the buildingskeleton construction shown in FIG. 1 in exploded form.

In FIG. 6 an alternate joint construction is shown wherein extensionrods 26a are welded to each of the top rods 26 of the tie beam and armat portions embedded in the concrete. The extension rods are butted andjoined by a crimped collar 31. This construction gives maximizedstrength against both compression and tension at the joints.

In some cases, the arms of the column components can be extended and theneed for tie beams eliminated by butting arms of adjacent columncomponents against each other and forming joints of the type shown inFIGS. 6 and 611. While it is preferred to use crimped connections. itwill be obvious to those skilled in the art that various jointarrangements can be made between the reinforcing rods of the componentsof this invention. In some cases. the reinforcing rods can extend beyondthe recesses or can comprise hook members for interlocking with adjacentends of similarly designed components. Of course the number ofreinforcing rods employed in each tie beam. arm. or column section canvary as desired depending upon the load to be placed on the structureand its ultimate desired strength in the module construction.

The floor/ceiling slabs of the present invention are preferably formedwith hollow chambers 35 as best shown in FIGS. 2. 2a. 2b. 3 and 4.Preferably four chambers 35 extend longitudinally through the slabs andpermit maintaining a desired thickness of concrete while reducing weightand thereby greatly increasing strength at least against forces appliedto the top and bottom of the slabs. The hollow chambers can be ofvarious sizes and dimensions depending on the type of core elements usedto form the chambers during molding of the floor/ceiling slabs.

Preferably the slabs each have reinforcing rods 36 of the typepreviously described extending both longitudinally and transversely.Preferably the side edges of the slabs each have a facing vertical wall37 and a rebated portion formed with reversely angled longitudinallyextending surfaces 40. The ends of the slabs are preferably each formedwith a vertical wall 39 and an angled inwardly extending surface 38.

The corners of the basic three slabs 12, 13 and 14 are designeddifferently depending on the position in which they are to lie on thebuilding skeleton. Thus. slab 12 has square corners and is adapted tolie in the middle of a bay as shown in FIG. 1 with its ends resting onopposed tie beams or arms. Slab 13 carries two corner portions 13areinforced with metallic supports 43 which are adapted to lie betweenthe bottom of one column and the top of another in the position shown inFIG. I. Slab 14 has slightly elongated ends with reinforced corners suchas 43 adapted to overlie cantilever sections of the cross arms assuggested in FIG. 1 with portions 43 positioned between the top of onecolumn and the bottom of another.

In the module building construction, the ceiling/floor slabs are laid ontop of the arms and tie beams as suggested in FIG. 1. Slabs 12 aresubstantially rectangular and are preferably middle slabs positionedwith their ends resting on parallel arms and tie beams and with theirsides adjacent corresponding slabs. Slabs such as 13 are placed on theoutside edge of a bay with two slabs 13 each overlying half of a tiebeam as best shown in FIG. 5. The floor/ceiling slabs can overlie eachbay formed in the building skeleton or, since the skeleton is rigid byitself, in some embodiments the top of at least some bays can be leftopened. Reinforcing rods 36 of the slabs extend outwardly of their endsand can be interlocked with adjacent slabs if desired although this isnot necessary.

FIG. illustrates positioning of two slabs 13 in side by siderelationship over a tie beam 30. Rebated side edges can be lockedtogether by filling the recess thcrebetween with conventional groutingas previously described. In the joint shown in FIG. 5 the transversereinforcing member 41 has an upwardly extending portion lying betweenthe side edges acting to further anchor grouting (not shown) whichcompletes the joint.

In most applications, the recess formed by the setback or rebated edgesof the ceiling/floor slabs are filled with grouting material which issufficient to smooth the surface on which top flooring may be laid andto lock the elements together due to the bending of the reinforcing rodends as illustrated at 42 and the reverse angle of surfaces 40.

The preferred joint between an upper column component 11 and anunderlying axially aligned column component 11 is best illustrated inFIGS. 7 and 7a. The lower portion of the upper column portion 16 isformed with extension reinforcing rods a welded or otherwise securedparallel to the ends of rods 25 which are cut off at the bottom edge 44of each portion 16. Thus, extensions 25a are parallel to reinforcingrods 25 and extend outwardly of the bottom 44 so as to lie parallel toand adjacent upwardly extending rods 25. The upper portions of the rods25 coming from the upper portion of a column are crimped together withtheir corresponding extension rods 250 by a collar such as 31 aspreviously described. As shown in FIG. 7 this joint provides for abutting face of each rod 25 of the upper column portion axially alignedwith a butting face of a rod 25 of the lower portion 44. The abuttingfaces act to bear some of the load while a rigid joint is formed by theextension portions 25a. In some cases collars 31 can be eliminated andthe rods 25 welded to extensions 25a. The extension portions 25a arepreferably molded in the columns when they are cast or prefabricated.Part of the load of the upper column 11 is borne by the metallic corners43 of the floor slabs as best shown in FIGS. 7a and 7. The collars 31can be welded to corners 43 as shown in FIG. 70 although this isoptional. Preferably metal angle irons 47 are cast in the bottoms andtops of the columns as best shown in FIG. 7 to provide load bearingedges and prevent chipping during erection of the skeleton. Thus.corners 43 extend between the bottom 44 and the top portion 45 of eachof the columns. Due to the spacing of the column portion 44 from portion45 by the floor slabs a recess 46 is formed in the joint between thecolumn components. Since there is a recessed edge to each floor slab asillustrated in FIGS. 4 and 70,

a crimping tool can be passed into the cavity 46 to form or crimp thecollars 31. Similarly grouting or suitable Waterproofing and gasketingmaterial can be positioned in the cavity 46 after completion of thecrimping operation to reinforce the joint construction.

In the alternate embodiments of the joints between the bottom 44 of onecolumn component 11 and the top 45 of a second column component 11,extension rods 2541 are eliminated. In the joint shown in FIGS. 7!] and7g the top of the column 11 is provided with a metallic facing plate apreferably welded or secured to top ends of reinforcing rods 25. Twocrossed U-shaped connecting rods are embedded in the column and havethreaded ends 1510: extending upwardly through holes provided in thefacing plate 150a. Preferably plate 150a carries four outwardlyextending tabs 152a through which ends 1510 extend. A second facingplate 153a preferably identical to plate 150a is welded to lowerportions of rods 25 at bottom 44. The plates 153a and 150a are butted injoining two column components 11 in vertical alignment and nuts 154aapplied and tightened to form a joint. This joint as Well as the jointillustrated in FIG. 7, will support the upper column component withoutthe need for bracing during construction or until the cross arms of theupper column are joined to supporting components. In this joint therecess 46 is eliminated.

In the embodiment of FIGS. 70 and 77:, identical fiat metallic plates180 are welded to rods 25 in the positions shown. Pairs of rods 25 ofeach column component pass through a plate 180 and form two upwardlyextending inverted parallel U-shaped extensions 181 and correspondingparallel downwardly extending U-shaped extensions 182. Extensions 181are offset from the axes of rods 25 as shown in FIG. 7h. Uponpositioning of the column components one above another extensions 181and 182 are parallel and define a passageway 183 in which a lockingwedge is positioned to lock the components together. After wedgelocking, conventional grouting is placed in recess 46 to complete thejoint.

In the embodiment of FIGS. 7d and 71', rods 25 extend upwardly anddownwardly from the top and bottom of each column and have enlarged ends155 with butting faces. A split collar 156 is crimped about facing ends155 at each of the four connections in the joint to form a rigid jointwhich supports the upper column. Grouting as previously described ispreferably used to fill recess 46 and complete the joint.

In the embodiment of FIGS. 7e and 7 the top of column component 11 has afiat plate 160 welded to ends of rods 25 with four outwardly extendingtabs 161 positioned preferably 90 degrees apart. Ends 162 of each tabare turned over preferably at an acute angle and their top edges 163define a first periphery greater than the periphery of column portion16. The bottom of column component 11 has a second plate 164 welded torods 25 and substantially identical to plate 160 but having its acuteangled tabs 165 bent over at 166 with edges defining a second peripherysmaller than said first periphery. In the joint, plates 160 and 164 butteach other and four wedges 167 are forced between each set of bent overtabs 162, 166 to form a rigid joint with the elimination of recess 46and the need for grouting. Of course any spaces at the joint can befilled with grouting if desired.

The wedge locking effect of the joint shown in FIGS. 7e and 7 can alsobe achieved with modification of plates 160, 164 as by the use ofcircular plates having overturned edges.

In the embodiment of FIGS. 7 and 7k, recess 46 is maintained asdescribed with relation to FIGS. 7 and 7a. Rods 25 are cut flush withtop 45 and two identical steel brackets 170 are embedded in crossformation in the top portion of column component 11. Brackets 170 aregenerally U-shaped in front view as shown in FIG. 7 and have integralinverted U-shaped freely extending portions 171 at either end.Preferably rods 25 of column portion 16 extend downwardly to butt endsof rods of top of an underlying column component 11. The bottom of thecolumn portion 16 carries two identical crossed, embedded, generallyVshaped steel brackets 173 having inverted U-shaped ends 174 extendingdownwardly. Ends 174 and 171 interlock as best shown in FIG. 7k tosupport the upper column component 11. Portion 171 can be bent over andinterlocked with portions 174 after positioning of the columns as shownin FIG. 7f. Preferably in this construction grouting is used to fillrecess 46 and complete the joint. The upper column component 11 shouldbe braced or supported in position until the grouting has hardened tocomplete the joint.

Turning now to the exterior wall slabs or panels, a typical wall panelis shown at 15 in FIG. 11, comprising a concrete layer 51 with aninterior thin concrete layer 52 sandwiching a foam or other insulatinglayer 53 therebetween. Preferably the concrete layer 51 is provided withhollow spaces or cores in the same manner as the floor slabs previouslydescribed. Reinforcing rods 54 or other conventional concretereinforcing means are preferably embedded in the layer 51. The side planview shown in FIG. 10 illustrates a module unit 15 which may for examplehave a width of four feet and a height of ten feet corresponding to acomplete module panel reaching from ceiling to floor. Heights of sevenfeet and three feet may also be provided for door and sill heightsrespectively. These three heights of the panels are sufhcient to providefor all exterior wall surfaces. FIGS. Ila, 11b and 110 show top views ofvarying size and configuration panels useful in outer wall construction.

FIG. 12 illustrates joining of two module panels such as 15 havingangled corners, to form a corner joint better illustrated in FIG. 16.The joint 60 has a gasket member 61 extending throughout the length ofthe joint in corresponding channels provided on facing 45 degree angledsurfaces of the panel edges. The gasket 61 as best seen in FIG. 24preferably comprises an elongated hollow cavity 62 and a resilientneoprene or other long-life rubber body portion 63. Preferably at leasttwo surfaces carry adhesive means 64 which can be any of the well-knownrubber cements covered by a conventional protective tear strip. Thisparticular gasket permits compression of the gasket causing a tight sealin addition to adhesive sealing which reinforces the seal and provides awaterproof joint having long life. Other gasket means can be used inplace of gasket 61.

FIG. 15 indicates still another joint between two wall panels 15employing a gasket 61 as above described.

Preferably all four edges of the wall panels 15 have embedded wingconnection means which rigidly join the panels to each other or to othercomponents of the building construction. The connection means 70comprises a pair of internally threaded tubes 71 having integral wingextensions wardly on each side thereof. A facing plate 73 is providedhaving apertures 75 and 76 aligned with the threaded apertures of thetubes 71. Tubes 71 are preferably embedded at the edges of the concretewall panels as best shown in F168. ll and 14 as is the facing plate 73.Pin connectors 77 are provided having a threaded end 78 and anon-threaded plug end 78a. Other connectors comprise flat headed screws79, Thus. when adjacent or stacked wall panels are to be connected,tubes 71 present in each panel are aligned and connecting pins such as77 as shown in FIG. 14 are used to form a joint. Where a flat floor 80or other material is to lie directly over the joint the flat headedscrew 79 is used as shown in FIG. 14. Preferably three connection means70 are provided on each peripheral edge of each exterior wall panel.

The connection means 70 can also be used in the floor slabs. Theconnection means serve a dual function in that they are used to formjoints and in addition are helpful in handling the panels or slabs.Thus, pins 77 can be positioned and used to attach lifting crane hooksto the 72 extending outwardly and downpanels to lift them into positionin a stack or building construction.

As best shown in FIG. 14, the panels 15 preferably have a hookedinwardly extending top 81 defining a means for keying and locking thewall panels 15 with a floor/ ceiling slab. The bottom of each wall panelpreferably has an angled wall 82 adapted to overlie the top angled wall83 of an identical panel 15 permitting a planar surface to be presentedon the outside of a building when wall panels 15 are stacked as in afirst and second story construction fragmentarily shown in FIG. 14. Thewall panels further interlock with the floor/ceiling slabs by the hookedportion 81 lying adjacent walls 40 as previously described. Variousconventional moldings such as 84 can be employed in the module buildingconstruction as shown in FIG. 14.

While panels 15 have been referred to as exterior wall panels they canalso function to provide room or partitioned sections in the interior ofa building structure of this invention.

Turning now to FIGS. 17, 17a, 17b, 17c, 17d and 18, a lightweightinterior sandwich panel construction is shown. The sandwich panel can beformed in module units as are the exterior wall panels 15 and preferablycomprises plywood outer layers 91 with an intermediate sandwichedorganic foam layer 92. The various layers can be varied as desireddepending on the particular application of the panels. FIGS. l7l7d"illustrate various modular sizes including floor to floor heights,spandrel heights and under beam heights. The widths of the panels alsovary as suggested in the drawings to provide for modular construction.

The interior sandwich panels 90 are preferably rectangular and carryfastening or joining and sealing means preferably on their vertical sideedges and top edge. A mating joining and sealing means 101 is used onbottom edges of panels to be positioned vertically over similar panels.A slightly altered form of the joining and sealing means 135 (FIG. 22)is mounted on the bottom edge of the panels 90 positioned in contactwith a floor. The joining and sealing means 100 is preferably an aluminum extrusion having a hacker plate 102 flush with the edge of thepanel and seated thereon by longitudinally extending webs 104. The webs104 can be locked to the panels during lamination of the sandwich layersto form a firm connection. Flange portions at the edges of the backerplate are angularly arranged slanting inwardly of the edges of the paneland outwardly of the backer plate as shown at 105 having a rabbetedrecessed portion 106 for receiving a sealing gasket as will bedescribed. A longitudinally extending channel 107 is formed by walls 108and 109 which have overturned inwardly extending lips or edge walls 110.The channel 107 is adapted to receive a barb such as 111 of a joiningclip 112.

The joining clip 112 is preferably formed of four spring metal stripseach having bent over flaps 113 at either end which extendlongitudinally with the backs of the strips joined together atlongitudinally extending lines 114 to form the barbs 111. The elongatedbent over strips 113 are adapted to be deformed when pressed into thechannel 107 and spring back to a locking position with the inturnedwalls as best shown in FIG. 20.

As shown in FIG. 20, four panels 90 are joined together at a corner by asingle joining clip member 112. The barb construction provides for rigidinterlocking while preventing passage of air from the outside throughthe joint construction due to the many bends that an air current musttake if it is to flow from one side of any panel through the joint toanother side of that panel or another panel.

As shown in FIG. 20, when a joint construction is formed. sealinggaskets 61 are positioned between the rabbeted portions 106 to furtherweatherize the joint and prevent passage of moisture or air. The barbjoint con- 9 structions permit vertical adjustment of the panels withrespect to each other after interlocking.

FIGS. 25, a, 25b and 26 illustrate various joint constructions possibleusing the extrusion and clip 112. In the corner section shown at 25!) aspecially designed corner flashing post is used to cover the outerextremity of the corner and provide an attractive appearance. Thisflashing unit 120 has an inner portion designed with a channel such as107 and a flat outer side. Similarly plates 121 can be formed with achannel 107 as previously described to cover interior sandwich panelsaligned with the same plane or at a three-corner intersection as shownin FIG. 25a.

As shown in FIG. 18, the joining extrusion 101 is formed with a barbmember 122 having bent over spring flaps 113 as previously described.Member 122 can be integrally formed with the extrusion 101 or can beattached as by welding of suitable folded strips of the type used inelement 112. Edges of the backer plate 102 in this embodiment extenddownwardly in the same plane as the faces of the panel 90 and areprovided with rabbeted edges 123 to mate with edges 105 and 106 of amember 100. A completed joint of this basic construction is shown inFIG. 21 where the extrusion is basically similar to 101. However, in theextrusion 130 shown in FIG. 21. extensions 104 are eliminated and screwsare used to attach the extrusion 130 to a ceiling under which the top ofa panel 90 may be connected.

FIG. 22 illustrates an elongated extrusion having a backer plate or base131 lying adjacent the elongated bottom edge of a panel 90. The base 131has downwardly extending side flanges 132 beneath which are positionedwedges 133 and 134. Upwardly extending legs 136 lie on either side ofthe wall panel. A channel such as 107 is provided on either upwardlyextending leg 136 and hooked over ends 139 form the top edges of thelegs 136. The extrusion 135 is adapted to have a baseboard strip 140clipped thereto by spring means as shown in FIG. 22. The baseboard strip140 has a spring member 141 attached to an overturned hook portion 139and a barb 111 as previously described to provide for positioning of thestrip 140 to cover the joint between the panel and a conventional floorsurfacing 142.

The wedges 133 and 134 which underlie member 135 preferably are used inpairs with two or more pairs spaced on the floor under each panel 90.The specific number of pairs of wedges used can be varied. These wedgeshave angled faces 143 and 144 and are slipped under the wall panels 90in the positions shown in FIG. 22. By pushing the wedges towards eachother in the position shown in FIG. 22, they raise portions of the panelinto proper alignment and locking engagement with a ceiling as theparallel grooved faces 143 and 144 catch with each other. Preferablyeach wedge has teeth 145 and 146 which are designed to permit slidingtowards each other in the position shown and prevent reverse sliding inuse. The leading face 146 of each tooth if extended meets the horizontalplane at angle A, the trailing face 147 of each tooth if extended meetsthe horizontal plane at angle B and the slope line C of each wedge blockmeets the horizontal plane at angle C. Angle A is always less than 20degrees and can be less. Angle B can be equal to angle A and angle C isno greater than 10 degrees. Angles A and C are interrelated in that byincreasing angle C angle A is increased relatively so long as face 147is not parallel to the horizontal plane. Both angle C and the size ofthe teeth should be small.

FIG. 19 illustrates still another joint construction possible with themodified clip arrangements of this invention. An extrusion 150 isprovided with members 104 as previously described for anchoring it tothe bottom of a wall panel under which a standard wall panel 90 is to bemounted. Extrusion 150 is basically similar to extrusion 101 but has anupwardly extending leg 136 as in extrusion 13S. Leg 136 of thisembodiment has predrilled holes 10 permitting attachment to panel 90 byconventional screws. The leg 136 can be integral with extrusion 150 orpreferably separate as shown with a plurality of rivets 148 joining italong its length to the extrusion.

In FIG. 23 there is illustrated still another extrusion 151 which actsas a door frame member. Extrusion 151 can be provided with a barb suchas 111, or as in the preferred embodiment with a plurality of holesalong its length through which nails 152 are inserted. Extrusion 1S1overlies and acts as 21 facing for the raw edge of a panel 90. Anelongated door stop molding 153 is preferably attached to extrusion 151by a plurality of screws 154 positioned along the length of the face ofextrusion 151.

From the above description, it will be understood that there is providedmodule components for the formation of single or multiple bays in abuilding skeleton and wall construction on a single level or on aplurality of levels. The components described can be put together invarious described configurations as desired. It is a feature of thisinvention that by preselecting the dimensions of the components, thenumber of components can be minimized to a small number of standardsizes. Thus, by using standard components. joints and sizes, one canplan a particular layout and immediately calculate the specific numberof each of the components and their standard sizes necessary forconstruction of the layout. For example, a single structural bay can bemade consisting of four column components 11, eight floor/ceiling panelsand four tie beams 30. Using a 4 0" dimensional module the cross armsare 90 from end to end of aligned arms. Tie beams 30 are 8-00 long.Column components 11 are 9'-4 high. The cross sectional dimensions ofthe concrete cross arms, tie beams and column portions 16 are 1 0 x l-4.The floor/ceiling panels are 6 in depth, 4'0 wide and l6-5" long. Withthese components a standard bay 260" x 26'0 is made with a maximumenclosed space which can be 676 sq. ft. The total amount of concretenecessary for such a bay would be 5075 cu. ft. weighing about 73,680pounds. Additional bays can be added by multiplying the number ofcomponents as desired.

While it is preferred to preform the components of this invention beforedelivery to a site where a building is to be constructed, the componentscan be formed on the construction site if desired.

Turning now to a description of core elements which are preferred foruse in forming the hollow spaces in the concrete slabs in accordancewith this invention, preferred embodiments of core elements are shown inFIGS. 27-32. It should be understood that these core elements are usefulto form hollow spaces or passageways in many types of moldedconstructions. Other core elements can be used in the slabs of thepresent invention.

An important feature of the novel core elements of thi invention is theuse of inexpensive, lightweight materials which can be shipped andstored flat and folded just prior to usage to an expanded form. Theexpanded form has an enclosed substantially hollow shape reinforced witha plurality of gusset members.

The word paper as used herein refers to lightweight stock sheet materialwhich preferably has a paper base. Preferably the paper materials areimpregnated or coated with waterproofing compounds in a known manner toprevent loss of strength when exposed to wet concrete during molding orcasting. Suitable materials include kraft paper, cardboard, corrugatedpaper and the like. In the preferred embodiment, forty point chip boardis used.

in the preferred embodiment of the core element shown in NO. 27, theelement 210 is formed from a flat sheet of chip board 211 cut in theoutline shown and having a series of prescored lines along which thesheet is to be folded in use. The sheet 211 can have substantial lengthsdepending upon the length of the hollow passageway desired in a concreteor other section to be cast. Normally the length will be at least fourfeet. Similarly the width of the sheet will be determined by the size ofthe hollow passageway desired. The sheet 11 can be shipped or stored inits flat form shown in FIG. 28.

The core element 210 is formed by folding along the prcscored linesindicated to form gusset members 212. 212. 213. 213'. 214, 214 outersections 215, 215', corner ortions 216, 216', 217, 217' and semicircularportion 218. Preferably the end edges of section 212 and 212' carry apressure-sensitive adhesive indicated at 223 and portions of walls 214and 214' carry a similar adhesive 224 which acts to hold the expandedform 210 in position when folded as shown in FIG. 27. After folding ofthe gusset members into the form shown in FIG. 27. end flaps 219. 219'are folded over to close the front end with tabs 220. 220 and 221, 221',which also carry pressure-sensitive adhesive, folded over and sealed toclose the float end. Similarly the rear end is closed by thecorresponding 1'tt1' wardly extending flaps.

The doubled over corner sections 216, 216' strengthen the structure andpermit support by conventional clips or wires in a mold cavity toposition the core elements and permit concrete or other material to bepoured therearound. After hardening of the poured material, the paperelements can remain in the concrete and due to their inexpensiveconstruction do not add materially to the cost of the final productswhich may be floor/ceiling slab as previously described. In some caseswhere the passageways extend to the end of the cast sections, the papermaterial can be removed from the passageways after formation andhardening of the concrete.

FIG. 31 illustrates an alternate embodiment wherein a single flat sheetis folded into a generally rectangular form 230 with adhesive means 231holding the ends of the sheet in a central portion thereof in place.Closing flaps similar to flaps 219. 219' can be used at ends of the form230. The zig zag gusset members are adhesively secured by adhesive means231.

In the alternate embodiment of the core element shown at 240 in FIGS. 29and 30, a flat sheet 249 is cut. Flaps 246 are positioned on section 241and have ends glued to the face of section 241 whereupon their free endscan be folded outwardly and transversely of a rectangular form to befolded with panels 242, 241, 243 and 244 as shown in FlG. 29.

The sheet 249 is preferably prescored along the lines shown and foldedinto the position shown in FIG. 29 just prior to use. The folding of thehinges of transverse gusset portions 246 is preferably accomplished bymeans of a tie string 245 passing through holes provided at the freeends of the gusset portions. The tie string is knotted to provide forpreselected spacing between the hinges when the rectangular outline isformed and the string pulled. As in the embodiment of FIG. 27. adhesivemeans can be used on the free end of panel 244 to lock the form inshape. End flaps 247 are employed along with adhesively connected tabs248 to close ends of the core element 240. In some cases the form shownin FIG. 29 can be constructed and then folded flat prior to shipment.

In the embodiment shown in FIG. 32. two separate elongated polygonalelements 250 and 260 are combined to form a single core element havingan expanded form. Element 250 has the cross sectional form of asix-sided figure wh le element 260 has a rectangular cross sectionaloutline. Each of the forms 250 and 260 can be expanded from flat sheetsor tubular elements can be formed and compressed into their fiat formfor shipment. Upon assembly of elements 250 and 260 element 250 isslipped within element 260 after first applying adhesive at points 261.262. 263, 264, 265 and 266. The adhesive can be precoated on the paperforms. When pressure-sensitive adhesives are used. conventional tearstrips which can be discarded overlie the adhesive strips. Water orother solvent activated adhesives may also be employed in any of theembodiments of this invention. Suitable end flaps can be provided toclose ends of the combined core elements shown in FIG. 32.

The scored lines between sections or panels of the geometric forms ofthe embodiments of FIGS. 27-32 can be conventional pressed lines orother weakened portions to facilitate folding. Alternatively, the foldlines may merely be printed on the sheet stock or eliminated if desired.

While specific embodiments of this invention have been shown anddescribed. it should be understood that many modifications thereof arepossible. For example, various ones of the elements can be substitutedwith other known structures. For example. the interior wall panels canbe eliminated and other conventional interior wall panels used. in somecases wall panels 90 can be used as exterior panels to form the facingof a building. Similarly, the various elements described can be used bythemselves in other constructions. The cross section of the column,cross arms and tie beams can be circular rather than square orrectangular as shown. The term cross formation" as used herein refers tothe use of at least two arms on the column components 11 although fourarms as in the embodiment of FIG. 1 is preferred. The various columnjoint constructions can be used to interconnect cross arms and ti: beamsor other elongated components in end to end relationship.

What is claimed is:

1. A modular lightweight wall panel for use in a modular buildingconstruction, said panel comprising side edges,

said side edges each carrying elongated fastening means for interlockingsaid edges with adjacent modular wall panels and for preventing movementof such interlocked panels away front each other while permittingsliding of said panels along a line fixed with respect to each other,

said fastening means comprises an elongated backer plate mountedadjacent each edge substantially coextensive therewith,

said backer plate having flange portions tapering inwardly of sides ofsaid panel and extending outwardly of said plate, and constructed andarranged to be received in facing engagement with corresponding flangeportions of a second backer plate on a second identical wall panel,

an integral elongated channel defined by joining walls extendingoutwardly of said backer plate, and said joining walls carrying integraloverturned edges facing each other.

2. A modular lightweight wall panel in accordance with claim 1 whereinsaid hacker plate flange portions are rabbeted to receive a gasketmeans.

3. A modular, lightweight wall panel in accordance with claim 1 whereinsaid fastening means is an integral extrusion and comprises,

elongated webs extending outwardly of said backer plate embedded in saidpanel to secure said backer plate to said panel.

4. A modular lightweight wall panel for use in a modular buildingconstruction. said panel comprising side edges.

said side edges each carrying elongated fastening means for interlockingsaid edges with adjacent modular wall panels and for preventing movementof such interlocked panels away from each other while permitting slidingof said panels along a line fixed with respect to each other,

an edge carrying an elongated backer plate coextensive therewith,

said backer plate having parallel side walls extending outwardly thereofand defining angled ends constructed and arranged to be received infacing engagement with a fastening means of an adjacent component,

and an elongated barb projecting from said backer 13 plate between saidside walls for interlocking said backer plate with another wall panel.

5. A modular lightweight wall panel in accordance with claim 1, andfurther comprising an elongated connecting member,

said connecting member having a central support with at least twoelongated outwardly extending spring barbs disposed at angles to eachother, each constructed and arranged to enter and lock said channel of awall panel with said connecting member.

6. A modular lightweight wall panel in accordance with claim whereinfour equally dimensioned barbs are provided spaced 90 degrees apartabout said central axis of said support.

7. A modular lightweight wall panel in accordance with claim 5 whereinsaid barbs are interlocked with the channels of four identical said wallpanels with a gasket means lying betwen portions of said facing edges.

8. A modular lightweight wall panel in accordance with claim 12 andfurther comprising said panel having a top edge positioned adjacent aceiling member, and a bottom edge,

wedge means underlying said bottom edge and urging said panel towardssaid ceiling member,

said wedge means comprising first and second wedge blocks each having aplurality of transversely extending teeth on inclined surfaces thereof,

said teeth each defining an inclined leading face defining a first anglewith a horizontal plane and a reverse face defining a second angle witha horizontal plane, and a third angle defined by the slope of theinclined surface of each block meeting with the horizontal plane,

said first angle being no greater than about 20 degrees and said thirdangle being no greater than about degrees.

9. A modular lightweight wall panel for use in modu lar buildingconstruction, said panel having side edges and front and rear surfaces,

at least one side edge carrying an elongated fastening means forinterlocking with an edge of an adjacent wall panel and for preventingmovement of such interlocked panels directly away from each other whilepermitting sliding of said panels along a line fixed with respect toeach other and substantially parallel to said one side edge,

said fastening means comprising hook means having a reversely bent hookportion for interlocking with a mating portion on an adjacent panel forsubstantially preventing movement of two interlocked panels directlyaway from each other without destruction of said hook means.

10. A modular lightweight wall panel in accordance with claim 12 wherein14 said hook means comprises an elongated channel defined by joiningwalls extending outwardly of said backer plate,

said joining walls carrying overturned edges facing each other,

and said gasket means are mounted in said backer plate.

11. A modular lightweight wall panel in accordance with claim 12 whereinsaid hook means comprises,

an elongated central support with two elongated outwardly extendingspring metal barbs disposed at an angle to each other.

12. A modular lightweight wall panel for use in modular buildingconstruction, said panel having side edges and planar front and rearsurfaces,

at least one side edge carrying an elongated fastening means forinterlocking with an edge of an adjacent wall panel and for preventingmovement of such interlocked panels directly away from each other whilepermitting sliding of said panels along a line fixed with respect toeach other and substantially parallel to said one side edge,

said fastening means comprising hook means for substantially preventingmovement of two interlocked panels directly away from each other withoutdestruction of said hook means,

said fastening means further comprising a backer plate carrying saidhook means and gasket means lying on either side of said hook means withsaid gasket means and hook means acting to provide a double seal againstpassage of fluids through joints between said interlocked panels.

References Cited UNITED STATES PATENTS 176,090 4/1876 Stewart 52-1221,294,115 2/1919 Knight 52586X 1,723,306 8/1929 Sipe 52--396X 2,664,740l/ 1954 Cochrane 52-583 2,947,040 8/1960 Schultz 52585X 3,203,149 8/1965Soddy 52588X 3,296,759 l/l967 Paulecka 524()3X 3,310,917 3/1967 Simon52624X 3,312,021 4/1967 Rolland 52l22 FOREIGN PATENTS 622,687 6/ 1967Canada 52-583 FRANK L. ABBOTT, Primary Examiner P. C. PAW, JR.,Assistant Examiner US. Cl. X.R.

